Instrumented component for wireless telemetry

ABSTRACT

A telemetry system for use in a combustion turbine engine ( 10 ) that includes a first sensor ( 306 ) in connection with a turbine blade ( 301 ) or vane ( 22 ). A first telemetry transmitter circuit ( 312 ) is affixed to the turbine blade and routes electronic data signals, indicative of a condition of the blade, from the sensor to a rotating data antenna ( 314 ) that is affixed to the turbine blade or is on a same substrate as that of the circuit. A stationary data antenna ( 333 ) may be affixed to a stationary component ( 323 ) proximate and in spaced relation to the rotating data antenna for receiving electronic data signals from the rotating data antenna. A second sensor ( 335 ) transmits electronic data signals indicative of the stationary component to a second telemetry circuit ( 332 ), which routes the signals to the stationary antenna. The stationary antenna transmits the electronic data signals to a receiver ( 338 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a Continuation-in-Part ofU.S. application Ser. No. 11/936,936 filed Nov. 8, 2007, now U.S. Pat.No. 8,519,866 and it also claims the benefit of U.S. ProvisionalApplication No. 61/300,184 filed Feb. 1, 2010, and U.S. ProvisionalApplication No. 61/300,188 filed Feb. 1, 2010, all of which areincorporated by reference herein in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to monitoring operatingenvironments and, in particular, to instrumented components andtelemetry systems enabled for wirelessly transmitting electronic dataindicative of individual component condition within an operatingenvironment such as that of a combustion turbine engine.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide high temperature wirelesstelemetry systems configured for operation on rotating or stationarycomponents within an operating environment having an operatingtemperature of approximately 450° C. or greater, such as within certainsections of a combustion turbine engine.

An exemplary high temperature telemetry system for use in a combustionturbine engine may include at least one sensor deposited on a componentsuch as a turbine blade. A telemetry transmitter circuit may be affixedto the turbine blade and a connecting material may be deposited on theturbine blade for routing electronic data signals from the sensor to thetelemetry transmitter circuit, the electronic data signals indicative ofa condition of the turbine blade. An induction power system is providedfor powering the telemetry transmitter circuit with a rotating dataantenna affixed to the component, such as the turbine blade; and astationary data antenna affixed to a static seal segment adjacent to theturbine blade.

In an embodiment of the telemetry system a resonant energy system isused in conjunction with the rotating data antenna and the stationarydata antenna. More specifically, a primary coil, or power/energytransmitting device, is positioned at a stationary location in theturbine or compressor proximate to a secondary coil or power/energyreceiving device that is affixed to the rotating components. The primarycoil transmits an oscillating current signal and the secondary coil isin resonance at generally the same frequency as a transmitting frequencyof the oscillating current signal. The secondary coil and the rotatingdata antenna are fabricated on a same substrate on which the telemetrytransmitter circuit is fabricated. Alternatively, one or both of thesecondary coil and/or the rotating data antenna may be disposed on anairfoil portion of a turbine or compressor blade. In an embodiment, theprimary coil may be mounted to a casing for the compressor or turbineproximate to and in spaced relation to a tip of the blade.

Sensors in connection with a rotating component such as a compressor orturbine blade are electrically linked to the telemetry transmittercircuit which processes and routes electronic data signals indicative ofa condition of the rotating component to the rotating data antenna. Therotating data antenna then transmits the electronic data signals to thestationary antenna which then transmits signals to a receiver and/orprocessor.

In another embodiment, a stationary telemetry transmitter circuit isdisposed within the compressor and turbine, and used in conjunction withthe above-referenced rotating telemetry transmitter circuit mounted to ablade. One or more sensors in connection with stationary componentstransmit electronic data signals indicative of the stationary componentto the stationary transmitter circuit, which in turn processes androutes the electronic data signals to the stationary data antenna.Accordingly, the stationary data antenna is configured to transmitelectronic data signals indicative of operating conditions of thestationary and rotating components to a receiver for processing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of an exemplary combustion turbine.

FIG. 2 is a perspective view of an exemplary combustion turbine vane.

FIG. 3 is a side view of the vane of FIG. 2.

FIG. 4 is an exemplary heat flux sensor deposited on a substrate.

FIG. 5 is a perspective view of an exemplary turbine blade, sensor andwireless telemetry device.

FIG. 6 is a schematic of an exemplary wireless telemetry device.

FIG. 7 is a partial perspective view of an exemplary compressor blade.

FIG. 8 is a partial side view of the exemplary compressor blade of FIG.7.

FIG. 9 is a partial cross sectional view of the exemplary turbine bladeof FIG. 5.

FIG. 10 is a perspective view of the exemplary turbine blade of FIG. 9,an exploded view of a telemetry transmitter housing and an exemplaryrotating antenna assembly mounted to the turbine blade.

FIG. 11 is an exploded view of an exemplary embodiment of the telemetrytransmitter housing of FIG. 10.

FIG. 12 illustrates components of an exemplary rotating antennaassembly.

FIG. 13 is a partial perspective view on a turbine static seal having anexemplary embodiment of a stationary antenna assembly mounted thereto.

FIG. 14 is a partial cross sectional view of the turbine static seal ofFIG. 12 and a turbine blade assembly having an exemplary rotating powerand antenna assembly mounted thereto.

FIG. 15 is a block diagram of an exemplary telemetry transmittercircuit.

FIG. 16 is a schematic of an exemplary induction power driver circuit.

FIG. 17 is a partial perspective view of a blisk having thereon wirelesstelemetry components including a sensor and a telemetry device.

FIG. 18 is a schematic illustration of a telemetry device linked to asensor.

FIG. 19 is a schematic illustration of circuits for a resonant energytransfer system.

FIG. 20 is a schematic representation of a rotating data antenna.

FIG. 21 is a sectional schematic illustration of a telemetry device on arotor of a blisk including a rotating data antenna on the blisk and astationary antenna on a stator.

FIG. 22 illustrates a transmitter device housed within an RF transparentcover.

FIG. 23 is an embodiment of the wireless telemetry system wherein anenergy receiving coil is on a blade for a blisk.

FIG. 24 is an embodiment of the wireless telemetry system wherein anenergy receiving coil and the rotating data antenna are on a blade for ablisk.

FIG. 25 is an embodiment of the wireless telemetry system wherein astationary telemetry circuit and stationary antenna are used to transmitdata relating to stationary components and rotating components.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an exemplary combustion turbine 10 such as a gasturbine used for generating electricity. Embodiments of the inventionmay be used with combustion turbine 10 or in numerous other operatingenvironments and for various purposes. Combustion turbine 10 includes acompressor 12, at least one combustor 14 (broken away) and a turbine 16.Compressor 12, combustor 14 and turbine 16 are sometimes referred tocollectively as a gas or combustion turbine engine 10. Turbine 16includes a plurality of rotating blades 18, secured to a rotatablecentral shaft 20. A plurality of stationary vanes 22 are positionedbetween blades 18, with vanes 22 being dimensioned and configured toguide air over blades 18. Blades 18 and vanes 22 will typically be madefrom nickel-based alloys, and may be coated with a thermal barriercoating (“TBC”) 26, such as yttria-stabilized zirconia. Similarly,compressor 12 includes a plurality of rotating blades 19 positionedbetween respective vanes 23.

In use, air is drawn in through compressor 12, where it is compressedand driven towards combustor 14. Combustor 14 mixes the air with fueland ignites it thereby forming a working gas. This working gastemperature will typically be above about 1300° C. This gas expandsthrough turbine 16, being guided across blades 18 by vanes 22. As thegas passes through turbine 16, it rotates blades 18 and shaft 20,thereby transmitting usable mechanical work through shaft 20. Combustionturbine 10 may also include a cooling system (not shown), dimensionedand configured to supply a coolant, for example, steam or compressedair, to blades 18 and vanes 22.

The environment within which turbine blades 18 and vanes 22 operate isparticularly harsh, subject to high operating temperatures and acorrosive atmosphere, which may result in serious deterioration ofblades 18 and vanes 22. This is especially likely if TBC 26 should spallor otherwise deteriorate. Embodiments of the invention are advantageousbecause components may transmit real time or near real time dataindicative of a component's condition during operation of combustionturbine 10.

U.S. Pat. No. 6,576,861, the disclosure of which is specificallyincorporated herein by reference, discloses a method and apparatus thatmay be used to deposit embodiments of sensors and connectors forconnecting sensors with transmitters or otherwise routing data signals.In this respect, methods and apparatus disclosed therein may be used forthe patterning of fine sensor and/or connector features of between about100 microns and 500 microns without the need of using masks. Multilayerelectrical circuits and sensors may be formed by depositing featuresusing conductive materials, resistive materials, dielectric materials,insulative materials and other application specific materials. Alternatemethods may be used to deposit multilayer electrical circuits, sensorsand connectors such as thermal spraying, vapor deposition, lasersintering and curing deposits of material sprayed at lower temperaturesmay be used as well as other suitable techniques.

FIG. 2 illustrates a pair of adjacent vanes 23 removed from compressor12 with one vane 23 having a sensor 50 mounted or connected thereto fordetecting a condition of the vane. A lead line or connector 52 may bedeposited as a means for routing a data signal from sensor 50 to atransmitter 54 configured for wirelessly transmitting the data signal toa transceiver 56. Connector 52 may be one or a plurality of electricalleads for conducting a signal from sensor 50 to transmitter 54.Alternate embodiments allow for various types of connectors 52 to beused as a means for routing a data signal from sensor 50 to transmitter54, depending on the specific application.

Transmitters 54 may be multi-channel and have various specificationsdepending on their location within a casing of combustion turbine 10.Transmitters 54 may be configured to function within the early stages ofcompressor 12, which are subject to operating temperatures of betweenabout 80° C. to 120° C. Transmitters 54 may be configured to functionwithin later stages of compressor 12 and/or stages of turbine 16 subjectto operating temperatures of greater than about 120° C. and up to about300° C. Transmitters 54 may be fabricated using silicon-on-insulator(SOI) technology and other materials capable of operating in regionswith temperatures greater than about 120° C.

FIG. 3 illustrates a schematic plan view of compressor vane 23 havingsensor 50 connected therewith and connector 52 connecting sensor 50 withtransmitter 54. A power source 51 may be provided, such as anappropriately sized battery for powering transmitter 54. Transmitter 54may receive signals from sensor 50 via connector 52 that aresubsequently wirelessly transmitted to transceiver 56. Transceiver 56may be mounted on hub 58 or on a surface external to compressor 12 suchas the exemplary locations shown in FIG. 1. Transceiver 56 may bemounted in various locations provided it is within sufficient proximityto transmitter 54 to receive a wireless data transmission, such as an RFsignal from transmitter 54.

One or more sensors 50 may be connected with one or more compressorvanes 23 by fabricating or depositing sensors 50 and connectors 52directly onto a surface of vane 23. Connector 52 may extend from sensor50 to a termination location, such as the peripheral edge of vane 23 sothat a distal end 53 of connector 52 is exposed for connection totransmitter 54. Sensor 50 and connector 52 may be positioned on vane 23to minimize any adverse affect on the aerodynamics of vane 23.Embodiments allow for a distal end 53 of connectors 52 to be exposed ata termination location, which may be proximate a peripheral edge of acomponent or other suitable location. This allows a field technician toquickly and easily connect connector 52 to a transmitter 54 regardlessof its location.

FIG. 4 illustrates an exemplary sensor 61 that may be deposited within abarrier coating such as TBC 60, which may be yttria-stabilized zirconia.TBC 60 may be deposited on a bond coat 62, which may be deposited on asubstrate 64. Substrate 64 may be various components such as asuperalloy suitable for use in turbine 16 such as a turbine blade 18.Sensor 61 may be formed for various purposes and may includethermocouples 66 deposited using conventional K, N, S, B and R-typethermocouple material, or any combination of their respectiveconstituent elements provided that the combination generates anacceptable thermoelectric voltage for a particular application withincombustion turbine 10.

Type K thermocouple materials NiCr or NiAl may be used in sections ofcompressor 12 having an operating environment up to approximately 800°C. For example, NiCr(20) may be used to deposit a strain gage incompressor 12. Type N thermocouple material, such as alloys of NiCrSiand NiSi, for example, may be used for depositing sensors in sections ofturbine 16 having an operating environment between approximately 800° C.to 1150° C.

Type S, B and R thermocouple materials may be used for depositingsensors in sections of turbine 16 having an operating environmentbetween approximately 1150° C. to 1350° C. For example, Pt—Rh, Pt—Rh(10)and Pt—Rh(13) may be deposited to form sensors 50 within turbine 16provided that the material generates an acceptable thermoelectricvoltage for a particular application within combustion turbine 10. Nialloys, for example, NiCr, NiCrSi, NiSi and other oxidation-resistantNi-based alloys such as MCrAlX, where M may be Fe, Ni or Co, and X maybe Y, Ta, Si, Hf, Ti, and combinations thereof, may be used as sensingmaterials for high temperature applications in deeper sections ofcompressor 12 and throughout turbine 16. These alloys may be used assensing material deposited in various sensing configurations to formsensors such as heat flux sensors, strain sensors and wear sensors.

Components within combustion turbine 10, such as blades 18, 19 and/orvanes 22, 23 may have application specific sensors 50 deposited toconform to a component's surface and/or embedded within a barrier orother coating deposited within combustion turbine 10. For example, FIG.5 shows an exemplary turbine blade 70, which may be a blade from row 1of turbine 16, having high temperature resistant lead wires, such asconnectors 72 deposited to connect an embedded or surface mounted sensor74 with a wireless telemetry device 76. Device 76 may be mounted in alocation where the telemetry components are exposed to relatively lowertemperatures, such as proximate the root 78 of blade 70 where theoperating temperature is typically about 150° C.-250° C. and higher.

Silicon-based electronic semiconductors, such as those that may be usedfor transmitting data, may have limited applications due to theiroperational temperature constraints. Temperature and performanceproperties of silicon and silicon-on-insulator (SOI) electronic chiptechnologies may limit their applications to operating environments ofless than about 200° C. Aspects of the invention allow for suchelectronic systems to be deployed for wireless telemetry device 76within compressor 12, which typically has an operating temperature ofabout 100° C.-150° C.

Embodiments of wireless telemetry sensor systems may be configured tooperate within higher temperature regions present in later stages ofcompressor 12, and within turbine 16. These regions may have operatingtemperatures of about 150° C.-250° C. and higher. Materials havingtemperature and electrical properties capable of operation in thesehigher temperature regions may be used for depositing sensors 50, 74,connectors 52, 72 and fabricating wireless telemetry devices 76.

Sensors 50, 74 and high temperature interconnect lines or connectors 52,72 may be deposited using known deposition processes such as plasmaspraying, EB PVD, CVD, pulsed laser deposition, mini-plasma,direct-write, mini-HVOF or solution plasma spraying. Typically, dynamicpressure measurements, dynamic and static strain, and dynamicacceleration measurements are desired on both stationary and rotatingcomponents of combustion turbine 10 together with component surfacetemperature and heat flux measurements. Thus, embedded or surfacemounted sensors 50, 74 may be configured as strain gages, thermocouples,heat-flux sensors, pressure transducers, micro-accelerometers as well asother desired sensors.

FIG. 6 is a schematic of a representative embodiment of a wirelesstelemetry device 76. Device 76 may be formed as a circuit board orintegrated chip that includes a plurality of electronic components suchas resistors, capacitors, inductors, transistors, transducers,modulators, oscillators, transmitters, amplifiers, and diodes eitherembossed, surface mounted or otherwise deposited thereon with or withoutan integral antenna and/or power source. Embodiments of wirelesstelemetry device 76 may be fabricated for use in compressor 12 and/orturbine 16.

Wireless telemetry device 76 may include a board 80, an electroniccircuit 90, an operational amplifier 92, a modulator 94 and an RFoscillator/transmitter 96 electrically connected with each other viainterconnects 98. The embodiment of FIG. 6 is an exemplary embodimentand other embodiments of device 76 are contemplated depending onperformance specifications and operating environments. Embodiments ofdevice 76 allow for a power source 100, and a transmitting and receivingantenna 102 to be fabricated on board 80 thereby forming a transmittersuch as transmitter 54 shown in FIGS. 2 and 3, or wireless telemetrydevice 76, shown in FIG. 5.

FIG. 7 illustrates a partial perspective view of an exemplary blade,such as a blade 110 having a blade root 112, which may be a compressorblade within compressor 12. One or more recesses or trenches 114 may beformed within root 112 such as within the bottom of blade root 112.Recesses 114 may be formed in various shapes or dimensions and locatedwithin blade root 112 at various places along its length. One or morerecesses or trenches 116 may be formed in one or more faces 118 of bladeroot 112. Recesses 116 may be formed in various shapes or dimensions andlocated within blade root 112 at various places within a face 118.Recesses 114, 116 may be formed using various methods such as by millingthem out after blade 110 is cast or by forming them as part of the blade110 mold.

FIG. 8 illustrates compressor blade 110 instrumented with components ofwireless telemetry device 76 affixed within blade root 112. In thisrespect, alternate embodiments of wireless telemetry device 76 allow forone or more electrical components 90, 92, 94, 96, 100, 102, shown inFIG. 6, to be mounted separately or contained on discrete boards 80 thatare electrically connected and affixed with an instrumented componentsuch as blade root 112. For example, a transmitting and receivingantenna 102 shown in FIG. 6 may be mounted separately from andelectrically connected with board 80 having a transmitter 122 formedthereon and being electrically connected with antenna 102.

Antenna 120 may be seated within recess 116 and transmitter 122 may beseated within recess 114. In this aspect, antenna 120 and transmitter122 are not mounted/embossed or deposited onto a board 80. In otherembodiments, antenna 120 may be deposited on a wireless telemetry board80, as shown in FIG. 6, and the data may be transmitted using wirelesstelemetry to a receiver such as a stationary mounted transceiver 56.Power source 100 may be integral with board 80 or located separatelyfrom the board and mounted as a discrete component.

FIG. 9 illustrates a partial view of an exemplary blade 130, which maybe a turbine blade such as one of the turbine blades 18. Turbine blade130 includes a root portion 132 defining an outer mold line for matingwith a rotor disk of turbine 16 within which blade 130 may be securedfor operation of combustion turbine 10. Sensing material may bedeposited on blade 130 or within a barrier coating deposited on theblade's surface to form a sensor 134. Connecting material may bedeposited to form connectors 140 so that data signals from sensor 134may be communicated to a transmitter 138 and subsequently to a rotatingantenna assembly 142. A recess 136 may be formed within a portion ofblade 130 so that one or more connectors 140 are seated below an outersurface of blade 130.

Transmitter 138 and antenna assembly 142 may be integrally secured withblade 130 so that the outer mold line defined by root 132 is notaltered. For example, transmitter 138 may be affixed to a transitionarea, or platform, above the fir tree portion of root 132 and antennaassembly 142 may be affixed to a face of root 132. Alternately, recessesmay be formed within the platform and face so that all or a portion oftransmitter 138 and/or antenna assembly 142 are seated below the surfaceof the outer mold line of blade root 172. Transmitter 138 and antennaassembly 142 may be secured within respective recesses using an epoxy oradhesive and a backfill material may be placed over them for protectionfrom high temperatures or particulates.

With respect to FIG. 5, wireless telemetry device 76 may be affixed toblade root 78 externally or embedded in such a way so that an outer moldline of the blade root is not significantly altered. Device 76 may beaffixed proximate blade root 78 so that it is contained within a cavitythat is created between the blade root 78 and a rotor disk of turbine 16when blade root 78 is inserted within the rotor disk. This enables aturbine blade 70 instrumented with sensor 74, connectors 72 and device76 to be installed into a mating segment of a rotor disk of turbine 16in the same manner as a turbine blade that is not instrumented. In thisrespect, instrumented blade 70 may be manufactured having all componentsnecessary for wirelessly extracting data indicative of various operatingparameters or conditions of blade 70 and/or a barrier coating depositedthereon and transmitting that data to a receiving device.

For example, one or more recesses or trenches may be formed into aportion of the substrate of blade 70, such as blade root 78, withinwhich one or more wireless telemetry devices 76 may be contained.Trenches may be formed by milling out desired regions of blade root 78and securing device 76 within the trench with an epoxy or other suitablebinder. The trenches may be back filled with a suitably high temperaturecement or ceramic paste to protect device 76.

Embodiments of the present invention allow for transmitting sensor datafrom a rotating component, such as a turbine engine blade 130 havingcertain electronic components located on root 132 of the blade, whichoperates in an environment having a temperature of between about 300°C.-500° C. For purposes of the disclosure herein, the term “hightemperature” without additional qualification will refer to anyoperating environment, such as that within portions of combustionturbine 10, having a maximum operating temperature of between about 300°C.-500° C.

Embodiments of the present invention provide components for use incombustion turbine 10 instrumented with telemetry systems that mayinclude one or more sensors, lead lines connecting sensors with at leastone telemetry transmitter circuit, at least one transmitting antenna, apower source and at least one receiving antenna. FIG. 10 illustratesturbine blade 130, a wireless telemetry transmitter assembly 150 androtating antenna assembly 142. Lead lines or connectors 152 may extendfrom one or more sensors, such as sensors 70, 134 to telemetrytransmitter assembly 150 when mounted proximate blade root 132. Leadlines 152 may route electronic data signals from sensor 70, 134 totelemetry transmitter assembly 150 where the signals are processed by atelemetry transmitter circuit formed on a circuit board contained withinan electronics package 154 shown in FIG. 11. Lead lines or connectors140 may be deposited for routing electronic data signals from atelemetry transmitter circuit to rotating antenna assembly 142.

FIG. 11 illustrates a high temperature electronics package 154 that maycontain a high temperature circuit board and form part of telemetrytransmitter assembly 150. The main body of electronics package 154 maybe fabricated from alloys such as Kovar, an alloy of Fe—Ni—Co. Thethermal expansion coefficient of Kovar ranges from about 4.5-6.5×10⁻⁶/°C., depending on exact composition. The Ni-based alloys typically usedfor high temperature turbine components, such as turbine blade 130 havethermal expansion coefficients in the range of about 15.9-16.4×10⁻⁶/° C.Electronics package 154 may be affixed securely in place while allowingfor relative movement between electronics package 154 and turbine blade130. This relative movement may result from their different thermalexpansion rates, which occur over time during the high number of thermalcycles between ambient air temperature and the >450° C. operatingtemperature typically experienced proximate blade root 132.

The telemetry transmitter assembly 150, as best shown in FIG. 11, mayinclude a mounting bracket 156 and a lid or cover plate 158 withelectronics package 154 positioned therebetween. A plurality ofconnecting pins 155 enable connection between an electronic circuitboard contained within package 154, such as one having a wirelesstelemetry circuit fabricated thereon, and various external devices suchas lead lines from sensors, induction coil assemblies and/or datatransmission antennae. Mounting bracket 156, cover plate 158 andretention screws 159 connecting them together may all be fabricated fromthe same material as is turbine blade 130. This ensures there is nodifference in thermal expansion between turbine blade 130 and mountingbracket 156. Consequently, no stresses are generated in mounting bracket156 and/or turbine blade 130 during thermal transients.

The thermal expansion coefficient of electronics package 154 may be lessthan that of mounting bracket 156 when the operating system within whichthese components reside is at a high temperature. Consequently,electronics package 154, including any circuit board contained therein,would expand less than mounting bracket 156, which may lead to damagecaused by vibrational energy in the system. In order to secureelectronics package 154 within mounting bracket 156 to accommodate thedimensional change differential between bracket 156 and electronicspackage 154, a layer of ceramic fiber woven fabric 160 may be placedbetween the electronic package 154 and the inside surface of mountingbracket 156. Fabric 160 may be fabricated from suitable ceramic fiber,including such fibers as silicon carbide, silicon nitride or aluminumoxide. For example, a quantity of Nextel™ aluminum oxide based fabric,manufactured by 3M, may be used for fabric 160.

With electronics package 154 and ceramic fiber woven fabric 160assembled with mounting bracket 156 and cover plate 158 to formtelemetry transmitter assembly 150, mounting bracket 156 may be attachedto turbine blade 130 by a suitable means for attaching, such as bolting,welding, brazing or via transient liquid phase bonding. FIG. 10illustrates a recess or flat pocket 162 that may be milled or otherwiseformed within turbine blade 130 proximate blade root 132 for receivingassembly 150.

Cover plate 158 may be formed with a flange 164 oriented perpendicularto the direction of G-forces, to add structural support to the coverplate, which counters the G-load forces occurring when rotating turbineblade 130 is operating at full speed. This relieves retention screws 159from carry the load applied to cover plate 158 via G-forces, and allowsthem to be made sufficiently small so that the telemetry transmitterassembly 150 fits in the relatively small recess 162 with nointerference with any adjacent components. If retention screws 159 wererequired to carry the load applied by the G-forces, their required sizewould be too large to fit in the available space.

FIG. 10 shows that rotating antenna assembly 142 may be affixed to theend face or neck of root 132. Assembly 142 may be an electronic assemblyhaving thermal expansion coefficients different than those of theNi-based alloys used for turbine hot gas path components such as turbineblade 130 including its root 132. One or more rotating antennaassemblies 142 may be protected from windage during rotation of turbineblade 130 at near the speed of sound. In an embodiment, the windageprotection material is transparent to RF radiation frequencies in orderto enable transmission of power and data through the material.

Embodiments of rotatable antenna assembly 142 may include a durable,protective, RF transparent cover 170 shown in FIGS. 10 and 12, which isessentially a hollow fixture within which a data antenna and inductionpower components are contained. RF transparent cover 170 protects itscontents from windage and hot gas ingress during operation of combustionturbine 10. Certain ceramics are suitable for protecting RF transmissionequipment from the elements at elevated temperatures. However, manyceramics and ceramic matrix composites are prone to chipping andcracking under the vibrational, impact and G-loading that a rotatingturbine blade 130 experiences during operation of combustion turbine 10.

The inventors of the present invention have determined that RFtransparent cover 170 may be fabricated from an RF transparent, hightoughness, structural ceramic materials. Ceramic matrix composites maybe used to fabricate housing 170 as well as material selected from afamily of materials known as toughened ceramics. Materials such assilicon carbide, silicon nitride, zirconia and alumina are availablewith increased toughness due to doping with additional elements and/ordesigned microstructures resulting from specific processing approaches.

One such material that is RF transparent, easy to form, and relativelyinexpensive is a material selected from a ceramic family generallyreferred to as zirconia-toughened alumina (ZTA). Ceramic materialselected from this family of aluminum oxide materials is considerablyhigher in strength and toughness than conventional pure aluminum oxidematerials. This results from the stress-induced transformationtoughening achieved by incorporating fine zirconium oxide particlesuniformly throughout the aluminum oxide. Typical zirconium oxide contentis between 10% and 20%. As a result, ZTA offers increased component lifeand performance relative to conventional pure aluminum oxide materials.

The designed microstructure of ZTA is fracture-resistant when theceramic is loaded in compression. However, if loaded sufficiently intension, the ceramic will fail catastrophically, as with traditionalceramic materials. Consequently, RF transparent cover 170 is designed sothat the tensile stresses in the ceramic material are minimized duringoperation of combustion turbine 10. This is accomplished by designingand fabricating such that (1) all corners, edges and bends of the ZTAcomponents are machined to eliminate sharp corners and edges, in orderto reduce the stress concentration factor at these locations, and (2)the orientation and fit of the ZTA component in a rotating antennaemounting bracket 174 is such that during operation the G-forces appliedto the ZTA box do not generate significant bending stresses in theattachment flanges. This is accomplished by orienting the flangesparallel with the G-loading direction, rather than perpendicular to theG-loading direction, so the ZTA flange is loaded in compression and notin bending.

FIG. 12 illustrates that a rotating antennae mounting bracket 174 may beassembled with RF transparent cover 170 to form rotating antennaassembly 142, as shown affixed to turbine blade 130 in FIG. 10. Theinterface loading between the rotating antennae mounting bracket 174 andthe RF transparent cover 170 minimizes the tensile stresses that occurin RF transparent cover 170. The design is such that the tensilestresses that occur in the RF transparent cover 170 are less than theminimum stress for fracture, resulting in long life for the structuralcomponent. Mounting bracket 174 may be made of the same metal as turbineblade 130 because the uniform thermal expansion coefficient between themwill result in minimal stresses being generated in the attachment regionduring heat-up and cool-down cycles.

Mounting bracket 174 may be designed so that all the G-loadingexperienced by rotating antenna assembly 142 during operation ofcombustion turbine 10 is absorbed in a direction extending toward upperend 178 of bracket 174, as indicated by arrow G in FIG. 12. No portionof mounting bracket 174 extends far enough past an antenna containedtherein to attenuate the RF transmission data signal. RF transparentcover 170 is secured in place so its internal stress field is primarilycompressive and may be retained using threaded pins (not shown) throughsemicircular divots on its flanges.

Mounting bracket 174 may be attached to a face of turbine blade root 132via conventional means such as welding, brazing, bonding, bolting orscrewing. An embodiment of rotating antenna assembly 142 may beassembled by placing desired antennae into the hollow body of RFtransparent cover 170, feeding lead wires 171 from the antennae outthrough holes formed within cover 170 and then filling the hollow bodyof cover 170 containing the antennae with a ceramic potting material.The potted RF transparent cover 170 containing the antennae may then beslid into mounting bracket 174, which may have been previously affixedto turbine blade root 132. Cover 170 may be secured to mounting bracket174 via pins inserted in holes in mounting bracket 174 and divots incover 170.

Embodiments of the present invention may be powered by various meanssuch as induced RF energy and/or by harvesting thermal or vibrationalpower within the combustion turbine engine 16. In the energy harvestedpower model, either thermoelectric or vibro-electric power could begenerated from the energy available in an operating combustion turbineengine 16. Thermopiles may be used to generate electricity from thermalenergy, or piezoelectric materials may generate electricity fromvibration of combustion turbine engine 16. Examples of these forms ofpower sources are described in U.S. Pat. No. 7,368,827, the entiredisclosure of which is incorporated herein by reference.

Embodiments of the present invention provide induced power modes forpowering components of wireless high temperature telemetry systems. Suchsystems may be configured as air-gap transformers where the transformerprimary induction coil assembly 186 is stationary and the secondaryinduction coil assembly 195 rotates. For example, an induced RF powerconfiguration is provided for powering a rotating telemetry transmittercontained within telemetry transmitter assembly 150. FIG. 13 illustratesa portion of a static seal segment 180 such as one that may be usedwithin the turbine engine 16 of combustion turbine 10. A plurality ofstatic seal segments 180 may encircle turbine engine 16 adjacent to aplurality of turbine blades 130. Static seal segments 180 may cooperatewith turbine blades 130 for sealing hot gas within a hot gas paththrough turbine engine 16 as recognized by those skilled in the art.

FIG. 13 shows an arcuate bracket 182 having respective channels orgrooves formed therein within which a stationary data transmissionantenna 184 and a stationary primary induction coil assembly 186 may besecured. Data transmission antenna 184 may be inserted into anon-conducting holder 185 for securing data transmission antenna 184with bracket 182. Non-conducting holder 185 ensures that datatransmission antenna 184 does not contact bracket 182, which may befabricated of metal, thereby ensuring correct operation. Non-conductingholder 185 may be fabricated from the same ZTA toughened ceramicmaterial used for the RF transparent cover 170. In the case of employingthe antenna 184 in an arcuate bracket 182, such as shown in FIG. 13,holder 185 may be segmented to provide flexibility, which allows forinstallation in curved bracket 182. The same segmented configuration maybe applied to the induction coil assembly 186 to enable installation ina curved bracket 182.

Primary induction coil assembly 186 and data transmission antenna holder185 may be formed with lobes in the region of attachment to bracket 182.The associated regions of material in the bracket 182 are removed in thesame lobe shape, with slightly larger size to accommodate installation.The lobe shape defines a radius of curvature that enables positiveretention of induction coil assembly 186 and antenna and holder 184,185, which may be placed into bracket 182 from an end and slid intoposition. The lobe shape enables positive retention to be maintainedwhile simultaneously ensuring that tensile stresses are not generated ininduction coil assembly 186 and antenna holder 185, both of which may befabricated of relatively brittle materials subject to structural failureunder tensile stresses.

The lobes may be positioned far enough from the front of induction coilassembly 186 and data transmission antenna 184 to ensure that metalbracket 182 does not interfere with functionality. Ceramic cement may beapplied between the surfaces of induction coil assembly 186 and antennaholder 185, and their respective pockets in bracket 182, in order toprovide a secure fit and accommodate thermal expansion differencesduring heat up and cool down. A thin plate (not shown) may be attachedon each end of bracket 182 that covers the lobed regions of theinduction coil assembly 186 and the data antenna 184, ensuring retentionduring operation.

One or more brackets 182 may be fabricated of the same alloy as staticseal segment 180, such as Inconel 625, and have an arcuate shape toconform to the interior surface of static seal segment 180. Bracket 182may be affixed to the interior surface of static seal segment 180 usingan interrupted weld 188 to minimize distortion of static seal segment180. Induction coil assembly 186 may include at least one stationarycore 190 and at least one stationary primary winding 192 with ‘H Cement’194 sold by JP Technologies encasing portions of stationary core 190.

FIG. 14 illustrates an embodiment having a rotating secondary inductioncoil assembly 195 contained within RF transparent cover 170, which maybe mounted proximate turbine engine blade root 132. The rotatinginduction coil assembly 195 may be fabricated from a core 200 andwinding 201, similar to the stationary induction coil assembly 186. Arotating data transmission antenna 202 may be provided for communicationwith stationary data transmission antenna 184. Data transmission antenna202 may be encased within a non-conducting holder 203, which may besimilar in construction as non-conducting holder 185. In an alternateembodiment, data transmission antenna 202 may be contained in RFtransparent cover 170, without use of non-conducting holder 203, inwhich case it may be held in place with a high temperature capablepotting material. Single or multiple stationary primary induction coils186 may be arranged on the interior surface of one or more static sealsegments 180 to form an arc that is circumscribed by rotating secondaryinduction coil assembly 195 and antenna 202 when combustion turbine 10is in operation.

One or more stationary primary winding 192 may be energized by highfrequency, high current power sources. The power can be supplied to eachstationary induction coil assembly 186 individually, or a series ofstationary induction coil assemblies 186 may be electrically connectedand driven by a single power supply. In an exemplary embodiment theremay be five adjacent, stationary induction coil assemblies 186 with eachdriven by its own power supply. The current flowing through eachstationary primary winding 192 creates a magnetic field in the rotatingsecondary induction coil assembly 195 that in turn creates a current inthe rotating secondary winding 201. The current from rotating secondarywinding 201 supplies power to a wireless telemetry transmitter circuitcontained within wireless telemetry transmitter assembly 150 asdescribed more fully herein below.

FIG. 14 illustrates that an initial gap “A” may exist between RFtransparent cover 170 and stationary core 190 prior to startup ofcombustion turbine 10. Initial gap “A” may be about 13 mm at startup ofcombustion turbine 10 and reduce to about 4 mm at baseload when turbineblade 130 and static seal segment 180 are closer together. Magnetic corematerials may be used to fabricate stationary core 190 and rotating core200. A magnetic material may be used as a core material in order tocouple the required power to a telemetry transmitter circuit containedwithin telemetry transmitter assembly 150 over the required gap “A.” Theselected magnetic material acts to focus the magnetic field produced bythe stationary primary windings 192 and received by one or more rotatingsecondary windings 201. This effect increases the coupling efficiencybetween the stationary and rotating elements.

Embodiments of induced power systems disclosed herein may employmultiple individual primary and secondary induction coil assemblies 186,195 to accommodate various geometries with combustion turbine 10. Forinstance, stationary induction coil assembly 186 and data transmissionprimary antenna 184 may need to span a certain distance of static sealsegment 180 in order to induce enough power to the system components andtransmit the required data. An embodiment of induction coil assembly 186and data transmission antenna 184 may need to be approximately four feetin length. In this example, for ease of fabrication, four individualpower/antenna assemblies each with a length of approximately one footmay be fabricated with respective brackets 182 and installed adjacent toone another on one or more static seal segments 180. If the end-to-endgap distance between the individual antennae is sufficiently small, thenthe antenna assembly will function as if it were a single, four-footlong antenna. Such antenna assemblies may be formed from straight orcurved elements thereby providing assemblies of varying lengths that arestraight, curved or otherwise configured as required by the specificapplication. In an embodiment, a plurality of such antenna assembliesmay span an arc of approximately 112 degrees in the top half of one ormore static seal segments 180 within turbine 16.

The inventors of the present invention have determined that a particularclass of magnetic core materials meets or exceeds the performancerequirements of embodiments of the present invention. The general termfor this class of materials is a nanocrystalline iron alloy. Onecomposition of this class of material is sold under the trade nameNAMGLASS® and has a composition of approximately 82% iron—with thebalance being silicon, niobium, boron, copper, carbon, nickel andmolybdenum. It has been determined that such nanocrystalline iron alloymaterial exhibits desirable characteristics such as a Curie temperaturegreater than 500° C., very low coercivity, low eddy-current loss, highsaturation flux density and the permeability is very stable over theentire high temperature operating range.

This nanocrystalline iron alloy material is commercially available intape-wound configurations in the form of toroids, or “C” coretransformer cores. Embodiments of the present invention utilize thisnanocrystalline iron alloy material to form an “I” core shape, which wasused for the primary stationary core 190. The “I” shape was selectedbecause this shape holds itself in place in the channel on stationarymounting bracket 182. The induction core 190 of each induction coilassembly 186 consists of a plurality of 0.007″ thick laminations ofnanocrystalline iron alloy material built up into an arc ofapproximately eleven inches in length. The same nanocrystalline ironalloy material may be used for the rotating antenna 200 transformercore.

The strength of the magnetic field used to couple power between thestationary and rotating elements may be increased by increasing thefrequency of the driving signal, i.e., the high frequency AC signalproduced by an exemplary induction power driver circuit illustrated inFIG. 16. Thus, embodiments of the present invention may employ a highfrequency to drive the stationary primary windings 192, such asfrequencies greater than approximately 200 kHz. Alternate embodimentsmay achieve an operating frequency of at least one megahertz with apower driver designed to operate at such frequencies.

The wire used for winding cores 190, 200 may be made of a 27%nickel-clad copper with ceramic insulation in order to reduce oxidationand failure at high temperatures. The handling characteristics of thiswire are significantly more challenging than standard organic-insulatedbare copper, as a result of the protective, ceramic coating, and specialtechniques were developed for the processes of winding both the primaryand rotating elements. Other wires may be insulated silver or anodizedaluminum.

Two types of ceramic materials may be used in the construction of boththe primary and rotating induction coil assemblies 186, 195. It isimportant to ensure the windings 192, 201 do not short (conduct) to thecore elements 190, 200. In addition to ceramic insulation supplied onthe wires, a compound, such as H cement, a ceramic cement with ultrafine particle size, may be used as an insulating base coat on thewinding cores 190, 200. Once the winding cores 190, 200 are wound theymay be potted with Cotronics 940, an aluminum oxide based ceramiccement.

FIG. 15 illustrates a schematic of an exemplary telemetry transmittercircuit 210 that may be fabricated on a circuit board fitted inside hightemperature electronics package 154 shown in FIG. 11, which is containedwithin telemetry transmitter assembly 150 shown in FIG. 10. Telemetrytransmitter circuit 210 may be configured for operation with a sensorsuch as sensor 134 of FIG. 9, which may be a strain gauge sensor formeasuring strain associated with turbine blade 130. The rotatingsecondary induction coil assembly 195 may provide approximately 250 kHzAC power to the voltage rectifier of transmitter circuit 210. Thiscircuit changes the AC input to a DC output and feeds the voltageregulator circuit.

The voltage regulator of transmitter circuit 210 maintains a constant DCvoltage output, even though the AC input voltage may vary. A constantvoltage output is required to achieve better accuracy and stableoperating frequency for the signal output. The voltage regulator alsosupplies a constant voltage to a strain gauge sensor 134 and a ballastresistor (not shown). The strain gauge sensor 134 and ballast resistorprovide the sensor signal input to the transmitter circuit 210. As thesurface where the strain gauge sensor 134 is mounted deflects, thestrain gauge changes resistance, which causes the voltage at thetransmitter circuit 210 input to change.

The varying voltage provided by the signal from the strain gauge sensor134 is amplified first by a differential amplifier and then by a highgain AC amplifier. The resulting signal is applied to a varactor diodein the voltage controlled oscillator (VCO) section of transmittercircuit 210. The VCO oscillates at a high carrier frequency. Thiscarrier frequency may be set in the band of 125 to 155 MHz with respectto transmitter circuit 210. The fixed carrier frequency is changedslightly by the changing voltage on the varactor. This change infrequency or deviation is directly related to the deflection or strainundergone by strain gauge sensor 134. The VCO carrier output is fed to abuffer stage and the buffer output connects to a transmitting antennacontained in the rotating antenna assembly 142 via lead wires 140 ofFIG. 10.

In a receiving device, such as transceiver 56 in FIG. 1 or other deviceslocated in high temperature or other areas within combustion turbine 10,the carrier signal is removed and the deviation becomes the amplifiedoutput that is proportional to strain. The transistors used in such atransmitter circuit 210 designed for high temperature use may befabricated from a high temperature capable material, such as wide bandgap semiconductor materials including SiC, AlN, GaN, AlGaN, GaAs, GaP,InP, AlGaAs, AlGaP, AlInGaP, and GaAsAlN, or other high temperaturecapable transistor material may be used up to about 500° C.-600° C.

Various embodiments of wireless telemetry transmitter circuit 210fabricated on a circuit board may be adapted for use within combustionturbine 10 at varying operating temperatures and with a range of sensortypes. Elements of transmitter circuit 210 and alternate embodimentsthereof may be fabricated using various temperature sensitive materialssuch as silicon-on-insulator (SOI) integrated circuits up toapproximately 350° C.; polysilseqioxane, PFA, polyimide, Nomex, PBZT,PBO, PBI, and Voltex wound capacitors from approximately 300° C.-350°C.; and PLZT, NPO, Ta₂O₅, BaTiO₃ multilayer ceramic capacitors fromapproximately 450° C.-500° C.

Various embodiments of resistors may be fabricated of Ta, TaN, Ti, SnO₂,Ni—Cr, Cr—Si and Pd—Ag for operating environments of approximately up to350° C. and Ru, RuO₂, Ru—Ag and Si₃N₄ for operating environments ofapproximately 350° C. and greater. Individual high temperatureelectronic components, such as discrete transistor, diode or capacitordie made from SiC, AlN, GaN, AlGaN, GaAs, GaP, InP, AlGaAs, AlGaP,AlInGaP, and GaAsAlN, or other high temperature capable semiconductingmaterial, may be replaced by a single SOI CMOS device for operation attemperatures not exceeding approximately 350° C.

With respect to the embodiment of the wireless telemetry device 76 shownin FIG. 6, the antenna 102, which may be a transceiver to receive and/ortransmit electrical signals, is fabricated on the same board as atelemetry transmitter circuit. The telemetry transmitter circuit mayinclude the electronic circuit 90, a multivibrator circuit (not shown),an operational amplifier 92, an RF modulator 94 and an RFoscillator/transmitter 96 electrically connected with each other viainterconnects 98. In addition to the foregoing components on the board80, the device 76 may include the power source 110 in electricalcommunication with the electrical circuit 90 and antenna 102. Theabove-described electrical components 90, 92, 94 and 96, including theantenna 102 and/or power source 110, are formed on a board or substrate80 in the form of a circuit board or an integrated chip. Alternatively,the power source 110 may be mounted off the substrate proximate a bladeor vane, or both the antenna 102 and power source are off the board, butremain in electrical communication with the telemetry transmittercircuit.

The embodiment shown in FIG. 6 and the embodiments shown in FIGS. 17-23,which are described in more detail below, may employ a resonant energytransfer assembly in which magnetic cores with windings are eliminated.These embodiments may be especially advantageous for use with smallermodular combustion turbine engines that are used in aeronautics. Morespecifically, such modular turbine systems for example incorporate ablisk that includes blades 301 integrally formed with a rotor disc 302that are significantly smaller than for example compressor or turbineblade stages used in power generation plants. Accordingly, the bliskdoes not have sufficient surface area available for supporting the powerinduction coil assemblies 186 and 195 including the magnetic cores 190and 200 shown in FIG. 14.

Moreover, in such modular turbine systems entire stages such as acompressor or turbine stage may be separated from an adjacent stage andreplaced. In separating stages, wiring of telemetry systems must be cutand reconnected, and the reconnected wires can be unreliable duringoperation of a turbine. A wireless telemetry system may eliminate thehard wiring that must be manually disconnected and reconnected whenremoving and replacing a compressor or turbine stage.

Components of the wireless telemetry system are shown in FIG. 17 withrespect to a blisk 300 which includes a plurality of blades 301integrally formed with a rotor disc 302. As shown, each blade 301includes a foil portion 303 over which hot expanding gas flows causingthe blisk 300 to rotate in the case of a turbine. In contrast, therotation of a compressor blisk draws hot gas past the rotating bladescompressing the hot gas as it is directed to the turbine stage of aturbine engine. Each blade 301 or foil portion 303 has a tip 304adjacent and in spaced relation to a casing 305 within which rotatingcomponents such as the blades 301 and stationary components such asvanes (not shown) are positioned. The blisk 300 may be positioned foroperation in a power turbine or compressor for a turbine engine. Inaddition, the below-described resonant energy transfer assembly may beused in connection with the monitoring of rotating components such asblades 301 or stationary components such as vanes.

An embedded or surface mounted sensor 306 is disposed on the blade 301relative to an area for which operating conditions of the blade 301 aremonitored. Temperature resistant lead lines or connectors 307electrically link the sensor 306 with a wireless telemetry device 308.The device 308 is preferably mounted in a location where telemetrycomponents are exposed to relatively lower temperatures such as therotor 309 of the blisk 300 where the operating temperature is typicallyabout 150° C. to about 250° C.

The sensor 306 and interconnect lines 307 may be deposited using knowndeposition processes such as plasma spraying, EB PVD, CVD, pulsed laserdeposition, mini-plasma, direct-write, mini-HVOF or solution plasmaspraying. Typically, dynamic pressure measurements, dynamic and staticstrain, and dynamic acceleration measurements are desired on bothstationary and rotating components of combustion turbine 10 togetherwith component surface temperature and heat flux measurements. Thus,embedded or surface mounted sensor 306 may be configured as straingauges, thermocouples, heat-flux sensors, pressure transducers,micro-accelerometers as well as other desired sensors. Moreover, thematerials used to fabricate the sensor may include those thermocouplematerials listed and described relative to the sensor 61 shown in FIG. 4for both the compressor or turbine components.

The embodiment of the wireless telemetry system shown in FIGS. 17-25includes a resonant energy transfer system having a primary coil 310mounted at a stationary location, within the compressor 12 or turbine10, relative to the rotating components of assembly including wirelesstelemetry device 308 and sensor 306. By way of example, and as shown inFIG. 17, the primary coil 310 may be mounted to a casing 313 of thecompressor or turbine and is linked to an RF power source 315. As shownin FIG. 18, the telemetry device 308 includes a telemetry circuit 312,such as that described relative to FIG. 15, and a power source in theform secondary coil 311. In addition, the transmitter device 308includes RF data antenna 314 that is in electrical communication withthe telemetry transmitter circuit 312.

The term “coil” as used herein in reference to the primary coil and thebelow-described secondary coil is not necessarily an indication of aphysical configuration of such a component. Indeed, one or both of the“coils” may be in the form of a probe. The term “coil” is intended toinclude a power transmitting and power receiving device that include theappropriately configured electrical components such as capacitors andinductors to generate an oscillating current from the primary device andinduces power in the secondary device which is tuned to resonate thatthe same frequency as that of the oscillating current.

In operation the primary coil 310, receiving power from the RF powersource 315, generates an oscillating magnetic field, and energy istransferred to the secondary coil 311 which powers the telemetrytransmitter circuit 312. The sensor 306 generates electronic datasignals, indicative of an operating condition of a component such asblades 301, and the electronic data signals are sent to the telemetrytransmitter circuit 312, which routes the electronic data signals to thedata antenna 314. The electronic data signals are indicative of anoperating condition of the component, such as the blade 301. In anembodiment, the device 308 may be fabricated as a circuit board or as anintegrated chip in which both the antenna 314 and the secondary coil 311are deposited on a substrate with circuit 312.

An exemplary circuit for the primary coils 310 and secondary coil 311for the transfer of energy is shown in FIG. 19 and includes primary coil310 which includes a transmitting coil or inductor L1 linked to a sourcecoil or inductor L3 via an air core transformer. Similarly, thesecondary coil includes a receiving coil or inductor L2 linked to asource coil L4 via an air core transformer. The transmitting coil L1 hasa resistance Rc and a resonating capacitor C; and, the receiving coil L2also includes a coil resistance Rc and a resonating capacitor C. In thisexemplary circuit, a source resistance Rs at the source coil L3 and theload resistance RL at the load coil L4 do not contribute to the Q of theresonant system, thereby increasing the coupling between the primarycoil 310 and the secondary coil 311 and, therefore, the distance thatpower can be transmitted. The respective RLC circuits for the primarycoil 310 and secondary coil 311 are tuned so that the coils 310 and 311are resonant at the same or common frequency so that power may betransmitted from the primary coil 310 to the secondary coil 311.

The coils 310 and 311 may be composed of temperature and oxidativeresistant materials such as Ni, an Ni-based superalloy, Incanel®, gold,platinum or other materials that are operative at temperatures of about250° C. or higher. In addition, an RF power driver may serve as thepower source to the primary coil so that coils are resonant at a commonfrequency between one MHz to about 15 MHz, and preferably at about 10MHz.

As noted above, the antenna 314 is printed on the circuit board, and adesired length of the can be calculated as follows:

$L = {\frac{\lambda_{D}}{4\sqrt{\left( {ɛ_{r} + 1} \right)/2}} = \frac{c/f}{4\sqrt{\left( {ɛ_{r} + 1} \right)/2}}}$wherein c is the speed of light in free space, f is the frequency ofcarrier signal and ∈_(r) is the dielectric constant of the substrate.For example, in connection with an LTCC (low temperature co-firedceramic) substrate, the f=80 MHz and ∈_(r)=6.7, an antenna length of 478mm, which is far beyond an allowable size for a circuit board.Accordingly, an antenna trace may be provided in a folded back and forthconfiguration. A layout of an exemplary monopole antenna is shown inFIG. 20. In addition, the secondary coil 311 should be sufficientlyseparated from the telemetry circuit 312 except for a connecting signalpath to avoid interference between the RF modulator and multivibratorcircuit of the telemetry transmitter circuit 312.

FIG. 21 illustrates a sectional view of a blisk 300 and stator 323 withan embodiment of the invention having a telemetry transmitter assembly316 contained within an RF transparent cover 317, which may be mountedproximate the rotor disc 302 of blisk 300 using bracket 318. Asdescribed above, the assembly 316 includes a telemetry circuit 312,secondary coil 311 and data antenna 314 fabricated in on the samesubstrate as an integrated chip. As seen in FIG. 22, connectors 319 areprovided to electrically connect the lead lines 307 and sensor 306 tothe telemetry transmitter circuit 312. In an embodiment, telemetrytransmitter circuit 312, secondary coil 311 and antenna 314 may besecured within the RF transparent cover 317 with a high temperaturecapable non-conducting potting material.

Again with respect to FIG. 21, the rotating data antenna 314 may beprovided for communication with stationary data antenna 320, which isinserted into a non-conducting holder 321 for securing data transmissionantenna 320 with bracket 322. The bracket 322 is mounted to a stationarycomponent as the stator 323, or a static seal segment associated withthe stator 323. Non-conducting holder 321 ensures that stationary datatransmission antenna 320 does not contact bracket 322, which may befabricated of metal, thereby ensuring correct operation. Non-conductingholder 322 may be fabricated from the same ZTA toughened ceramicmaterial used for the RF transparent cover 317. In the case of employingthe antenna 320 in an arcuate bracket, such as shown in FIG. 13, holder322 may be segmented to provide flexibility, which allows forinstallation in a curved bracket. In an embodiment, the stationaryantenna 320 may extend circumferentially on the stator 323 so thatelectronic data signals may be received from the rotating data antenna314 at any point or time during operation of the turbine engine. Asshown, an electrical lead wire 340 electrically connects the stationaryantenna 320 to a controller or processor 341 so that the electronic datasignal received from the rotating data 314 are transmitted forprocessing to monitor the operating conditions of the blade 301.

In yet another embodiment shown in FIG. 23, the secondary coil 311 maybe deposited on the tip 304 of the foil portion 303 of blade 301. Asshown, an electrical lead line 324 is also deposited on the blade 301electrically connecting the coil 311 to the telemetry circuit 312affixed to the rotor disc 302 in the manner described above. In such anembodiment, the rotating data antenna 314 may be fabricated on thecircuit board 80 with the telemetry circuit 312, which may furtherreduce the size of the board 80 as necessary.

In reference to FIG. 24, another embodiment of the invention, both thesecondary coil 311 and the rotating data antenna 314 are deposited onthe foil portion 303 of the blade 301. As described above, theelectrical lead line 324 electrically connects the coil 311 to thetelemetry transmitter circuit 312 thereby powering the circuit 312. Inaddition, the electrical lead line 325 routes electrical data signalsfrom the transmitter circuit 312 to the rotating data antenna 314. Insuch an embodiment, where the antenna 314 is on the blade 301 and not onthe substrate of the telemetry circuit 312, an RF transparent cover isnot required. The telemetry circuit 312 may be housed in an electronicspackage as shown in FIG. 11, and mounted to the rotor disc 302.

With respect to FIG. 25, there is illustrated an embodiment of awireless telemetry system including a resonant energy transfer systemthat includes two telemetry transmitter devices 330 and 331, each ofwhich includes a telemetry transmitter circuit. More specifically, thesystem includes a first or rotating transmitter device 330 and a secondor stationary transmitter device 331. FIG. 25 is a sectional view of arotating component such as the above-described blisk 300 of a turbine orcompressor, which may also represent a turbine blade stage of largercompressors and turbines. In addition, the blisk 300 is positionedadjacent a stationary component such as a stator 323.

As described above, the first (or rotating) telemetry device 330 mayinclude a telemetry transmitter circuit 312, a data antenna 314 and asecondary coil 311 fabricated as an integrated chip. Alternatively,either one or both of the data antenna 314 and/or secondary coil 311 areon the blade 301 or airfoil 303. In addition, one or more sensors 306are disposed on a portion of the blade 301 that is intended to bemonitored during operation of the compressor 12 or turbine 10.Electrical lead lines 307 connect the sensors 306 to the telemetrytransmitter circuit 312 in order to route electric data signals,indicative of an operating condition of the blade 306, to the telemetrytransmitter circuit 312. The transmitter circuit 312 is electricallyconnected to the first antenna 314 to route the electric data signals tothe antenna 314.

As shown, the telemetry system includes a primary coil 310 that islinked to an RF power source 315, supplies a current or power to theprimary coil 310. The primary coil 310 is positioned at a stationarylocation relative to blisk 300, such as a turbine or compressor casing305. As described above, the primary coil 310, receiving power from theRF power source 315, generates an oscillating magnetic field, and energyis transferred to the secondary coil 311 which powers the telemetrytransmitter circuit 312.

Assuming that the antenna 314 is fabricated on the same substrate as thetelemetry circuit 312, the telemetry device 330 includes an RFtransparent cover 314 and bracket 318 to affix the circuit 312 to therotor disc 302 of the blisk 300. An RF transparent cover is not requiredif the antenna 314 is disposed on the blade 301 or some other locationon the blisk 300 and off the substrate of the telemetry transmittercircuit 312.

In the embodiment shown in FIG. 25, the wireless telemetry system alsoincludes a mechanism for acquiring and transmitting electronic datasignals indicative of a condition of a stationary component within theturbine 10 or compressor 12. Accordingly, a second or stationarytelemetry device 331 is affixed to the stator 323. Similar to the firsttelemetry device 330, the second telemetry device 331 includes atelemetry circuit 332 and antenna 333 (also referred to as a stationaryantenna or second antenna), that are fabricated on a substrate in theform of an integrated chip; however, the antenna 333 may be affixed tothe stator apart from telemetry circuit 333 as shown in FIG. 22.

As further shown in FIG. 25, one or more sensors 335 are positioned atstationary locations in the compressor 12 or turbine 10, to monitorconditions of the stator 323 or other stationary components. Electricallead lines 334 electrically connect the sensors 335 to the second orstationary telemetry circuit 332 to transmit electronic data signalsindicative of the condition of a stationary component to the secondtelemetry circuit 332. The telemetry circuit 332 is in electricalcommunication with the second or stationary antenna 333 to route thesignals to the antenna 333. The stationary antenna 333 may be fabricatedon the same substrate as that of the telemetry circuit 332, or may beseparately mounted as shown in FIG. 21. Moreover, the RF transparentcover 317 is not required for the second telemetry circuit 332 orantenna, as operating conditions such as temperature may not be asextreme relative to the blade 301 and disc 302.

In a preferred embodiment, a power source 336 is linked to the secondtelemetry circuit 332 via an electrical lead line 337. This electricalconnection may be necessary in order to provide sufficient power to thetelemetry circuit 332 to route signals from the sensors 335 to theantenna 333 and further transmit the electronic data signals from thesecond or stationary antenna 333 to a receiver 338. As shown, thereceiver 338 is mounted at a stationary location proximate the secondantenna 333 and is linked to a controller or processor 339 forprocessing the electronic signals that are indicative of operatingconditions of stationary and rotating components. The antenna 333 isconfigured to transmit electronic data signals received from thestationary sensors 335 and telemetry circuit 332 as well as electronicdata signals transmitted from the rotating antenna 314. The electronicdata signals may be transmitted from the stationary antenna 333 eitherwirelessly or via an electronic lead wire (not shown). In this manner,the stationary antenna 333 receives and transmits electronic datasignals relative operating conditions of both stationary and rotatingcomponents of a turbine 10 or compressor 12.

While the preferred embodiments of the present invention have been shownand described herein, it will be obvious that such embodiments areprovided by way of example only. Numerous variations, changes andsubstitutions will occur to those of skill in the art without departingfrom the invention herein. Accordingly, it is intended that theinvention be limited only by the spirit and scope of the appendedclaims.

The invention claimed is:
 1. A wireless telemetry system for monitoring operating conditions of a component of a combustion turbine engine having a compressor and a power turbine, the wireless telemetry system comprising: at least one first sensor in connection with a rotatable component of the combustion turbine engine; a first telemetry transmitter circuit affixed to the rotatable component, and the first telemetry transmitter circuit in electrical communication with the at least one first sensor, wherein electronic data signals indicative of a condition of the rotatable component are routed to the first telemetry transmitter circuit; a resonant energy transfer system for powering the first telemetry transmitter circuit, wherein the resonant energy transfer system comprises a primary coil and a secondary coil, wherein the primary coil is arranged to transmit an oscillating current signal, wherein the primary coil is affixed to an area of the turbine engine in spaced relation to the secondary coil, wherein the secondary coil is in resonance at generally the same frequency as a transmitting frequency of the oscillating current signal transmitted by the primary coil, wherein the rotatable component comprises a blade having an airfoil across which expanding hot gas flows, wherein the primary coil is mounted to a casing of the combustion turbine engine, wherein the primary coil is located proximate a tip of the airfoil of the rotatable component, wherein the secondary coil comprises an electrically conductive material disposed on the airfoil of the rotatable component, wherein the electrically conductive material is in electrical communication with the first telemetry transmitter circuit; a first data antenna affixed to the rotatable component, wherein the first data antenna is in electrical communication with the first telemetry transmitter circuit to receive the electronic data signals indicative of the condition of the rotatable component; a second data antenna affixed to a stationary location of the combustion turbine engine in spaced relation to the first data antenna to receive from the first data antenna the electronic data signals indicative of the condition of the rotatable component; at least one second sensor in connection with a stationary component of the combustion turbine engine; and a second telemetry transmitter circuit powered by the energy transfer system, or another power source, the second telemetry transmitter circuit affixed to a stationary location of the combustion turbine engine, the second telemetry transmitter circuit in electrical communication with the at least one second sensor, wherein electronic data signals indicative of a condition of the stationary component are routed from the at least one second sensor to the second telemetry transmitter circuit; wherein the second data antenna transmits to a receiver electronic data signals indicative of the condition of the stationary component, and further transmits to the receiver electronic data signals indicative of the condition of the rotatable component.
 2. The wireless telemetry system of claim 1, wherein the first data antenna comprises an electrically conductive material disposed on the airfoil of the rotatable component.
 3. The wireless telemetry system of claim 1, wherein the first telemetry transmitter circuit is configured on a substrate affixed to the rotatable blade and the first data antenna is disposed on the same substrate and in electrical communication with the first telemetry transmitter circuit, wherein the first telemetry transmitter circuit and the first data antenna on the substrate are housed in a radio frequency (RF) transparent cover.
 4. The wireless telemetry system of claim 3, wherein the RF transparent cover, with the first telemetry transmitter circuit and the first data antenna, is mounted to an end face of the blade or a rotor disc facing the stationary component on which the second data antenna is mounted.
 5. The wireless telemetry system of claim 1, wherein the secondary coil is resonant at a frequency in a range from approximately 150 kHz to 15 MHz.
 6. The wireless telemetry system of claim 1, wherein the second data antenna is housed in an RF transparent cover affixed to the stationary component of the turbine engine proximate the first data antenna.
 7. The wireless telemetry system of claim 1, wherein the second data antenna is supported in a holder composed of a non-conducting material mounted to the stationary component.
 8. The wireless telemetry system of claim 1, wherein the turbine engine is a modular system including the compressor and turbine engine that are separable from one another.
 9. A wireless telemetry system for monitoring operating conditions of a component of a combustion turbine engine having a compressor and a power turbine, the wireless telemetry system comprising: a first sensor in connection with a rotatable blade attached to a rotor disc of the combustion turbine engine; a first telemetry transmitter circuit affixed to the blade at a location having an operating temperature of about 500° C.; a first electrical connecting material on the blade for routing electronic data signals from the first sensor to the first telemetry transmitter circuit, the electronic data signals indicative of a condition of the blade; a resonant energy transfer system for powering the first telemetry transmitter circuit, wherein the resonant energy transfer system comprises a primary coil and a secondary coil, wherein the primary coil is arranged to transmit an oscillating current signal, wherein the primary coil is affixed to an area of the turbine engine in spaced relation to the secondary coil, wherein the secondary coil is in resonance at generally the same frequency as a transmitting frequency of the oscillating current signal, wherein the rotatable blade has an airfoil across which expanding hot gas flows, wherein the primary coil is mounted to a casing of the combustion turbine engine, wherein the primary coil is located proximate a tip of the airfoil of the rotatable blade, wherein the secondary coil comprises an electrically conductive material disposed on the airfoil of the rotatable component, wherein the electrically conductive material is in electrical communication with the first telemetry transmitter circuit; a first data antenna affixed to the blade or rotor disc, wherein the first data antenna is in electrical communication with the first telemetry transmitter circuit to receive electronic data signals from the first telemetry transmitter circuit; a radio frequency (RF) transparent cover arranged to house the first telemetry transmitter circuit and the first data antenna; a second data antenna positioned on a stationary surface of the combustion turbine engine proximate to and in spaced relation to the first data antenna for receiving electronic data signals from the first data antenna; a second sensor in connection with a stationary component of the combustion turbine engine; a second telemetry transmitter circuit affixed to a stationary location of the combustion turbine engine, the second telemetry transmitter circuit configured to process electronic data signals received from the second sensor, the electronic data signals indicative of an operating condition of the stationary component; a power source, apart from the energy transfer system, for powering the second telemetry transmitter circuit; and a receiver, in space relation to the second data antenna, the receiver arranged to receive from the second data antenna the respective electronic data signals indicative of the operating condition of the blade and the stationary component.
 10. The wireless telemetry system of claim 9, wherein the telemetry transmitter circuit is formed on a substrate affixed to the blade or the rotor disc and the first data antenna is disposed on the same substrate as that of the telemetry transmitter circuit.
 11. The wireless telemetry system of claim 9, wherein the blade is one of a plurality of blades integrally formed with the rotor disc forming a blisk in a modular turbine machine wherein the compressor and turbine are separable from one another. 